Terminal Sensor Array

ABSTRACT

An apparatus having a conducting probe configured to couple with an electrical conductor of an electrical terminal. The apparatus has a sensor in contact with the conducting probe. The apparatus has a controller electrically coupled to the sensor, where the controller is configured to monitor the sensor values, and when the sensor values comply with a monitoring rule associated with a hazardous condition, the controller is configured to initiate an action to mitigate the hazardous condition.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. provisional patentapplication Ser. No. 62/893,253, filed Aug. 29, 2019, entitled “TERMINALSENSOR ARRAY,” which is hereby incorporated by reference in itsentirety.

BACKGROUND

The present disclosure relates to the field of electronic components anddevices containing electronic components.

The terminals of power devices may have low contact resistance to, forexample, limit power losses and/or reduce heat generation. The terminalsize/type and wire gauge may be determined by the maximum currentrating. For low currents, thin wires and small terminals may be used,and for high currents, large wires and terminals may be used. Units areabbreviated here and throughout the disclosure as millimeter (mm),millimeter square (mm²), 1000 circular mils (kcmil), meter (m),milli-ohm (mΩ), degrees centigrade (° C.), and amperes (A). For example,a wire gauge of 8 American Wire Gauge (AWG) may have a maximum currentrating of 20 A (when at 6 meters length) and may be connected to aterminal block, such as WAGO® model 284401. For example, a wire gauge of6 AWG may have a maximum current rating of 70 A (when up to a length of3 meters) and use a terminal having at least as a 16 mm² wire crosssection capability, such as Weidmüller® type WPE 10 part number1010300000. Wire gauges may range from very small sizes to very largesize, where some of the sizes are listed in the following table:

TABLE 1 Copper wire Ampacity, at 20° C. insulation material Resistance/temperature rating Diameter Area length 60° C. 75° C. 90° C. AWG (mm)(kcmil) (mm²) (mΩ/m) (A) 0000 (4/0) 11.684  212 107 0.1608 195 230 260 000 (3/0) 10.405  168 85 0.2028 165 200 225  00 (2/0) 9.266 133 67.40.2557 145 175 195   0 (1/0) 8.251 106 53.5 0.3224 125 150 170 1 7.34883.7 42.4 0.4066 110 130 145 2 6.544 66.4 33.6 0.5127 95 115 130 3 5.82752.6 26.7 0.6465 85 100 115 4 5.189 41.7 21.2 0.8152 70 85 95 5 4.62133.1 16.8 1.028 6 4.115 26.3 13.3 1.296 55 65 75 7 3.665 20.8 10.5 1.6348 3.264 16.5 8.37 2.061 40 50 55 9 2.906 13.1 6.63 2.599 10 2.588 10.45.26 3.277 30 35 40 11 2.305 8.23 4.17 4.132 12 2.053 6.53 3.31 5.211 2025 30 13 1.828 5.18 2.62 6.571 14 1.628 4.11 2.08 8.286 15 20 25 151.45  3.26 1.65 10.45 16 1.291 2.58 1.31 13.17 18 17 1.15  2.05 1.0416.61 18 1.024 1.62 0.823 20.95 10 14 16

For multiple terminals located adjacent to one another, terminal blocksattached to a support may be used. The terminal blocks comprise multipleterminals arranged in tiers or along rows, and may be mechanicallycoupled to a support, such as a rail, a printed circuit board, or anenclosure. When mechanically coupled to a wall of a structure or anenclosure, a Deutsches Institut für Nonnung (DIN) rail may be used. TheDIN rail is a metal profile, usually from cold rolled steel with zincplating, where the DIN rail is attached to a wall, cabinet, and/or adevice enclosure, using bolts or screws, and the DIN rail holds terminalblocks in place. The terminal blocks may snap on to the DIN rail.Although made form a conducting metal, the DIN rail is not used as abulbar for conducting electrical current, but may be used as anelectrical ground connection. DIN rails may have a top hat profile (suchas top hat rail IEC/EN 60715-35×7.5), a C-section profile (such as AS2756.1997 C20 or C30), or a G-section profile (such as EN 50035, BS5825, or DIN 46277-1).

DIN rail terminal blocks may have one or more recesses for incorporationof jumpers, such as bridge jumpers, where the jumpers may be used toconnect electrically between two otherwise electrically isolatedterminals. A recess passes through the housing and internal conductor ofeach terminal block, and may have a shape and size with a cross sectionmatching the current rating of the terminal block, a mechanical strengthrequirement. The recess through the internal conductor is sized slightly(such as 1 mm) smaller than the recess size of the housing. Theterminals connected by the jumper may be adjacent, non-adjacent,consecutive, and/or alternating. In some configurations, additionalterminals may be incorporated onto the jumper to allow electrical accessto the main conductor of the terminal block.

SUMMARY

The following summary is a short summary of some of the inventiveconcepts for illustrative purposes only and is not an extensiveoverview, and is not intended to identify key or critical elements, orto limit or constrain the inventions and examples in the detaileddescription. One skilled in the art will recognize other novelcombinations and features from the detailed description.

According to aspects of the disclosure herein, an apparatus comprisesone or more thermal conductors configured in size and shape to fit intoone or more recesses of a DIN rail terminal block, and couple thermallywith internal conductors of the terminal blocks. Temperature sensors arein thermal contact with the thermal conductors, and convert the sensedtemperatures to electrical properties, such as a voltage, a current, aresistance, and/or an impedance. Conductors may electrically couple thesensors to a circuit, transferring the electrical property to thecircuit. The circuit may comprise a digital controller that ray convertthe electrical properties from the sensors to digital values. Thecircuit may comprise an analog controller circuit that may convert theelectrical properties (analog values) from the sensors to a mitigatingaction using analog components. As used herein, the term controllercircuit may mean an analog controller circuit, a digital controllercircuit, or a combined analog and digital controller circuit, and theterm controller may be used in lieu of controller circuit. Thecontroller circuit may monitor the temperatures of the internalconductors of the terminal blocks, and when the temperatures of one ormore internal conductors is abnormal, the controller may mitigate theabnormality, such as by sending a notification and/or lowering thecurrent passing through that terminal.

As noted above, this Summary is merely a summary of some of the aspectsand features described herein. It is not exhaustive, and it is not to bea limitation on the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood with regard to the followingdescription, claims, and drawings. The present disclosure is illustratedby way of example, and not limited by, the accompanying figures. In thedrawings, like numerals reference similar elements.

FIG. 1A shows, schematically, an example terminal block jumper pass-thrusensor apparatus.

FIG. 1B shows, schematically, an example terminal block sensorapparatus.

FIG. 1C shows, schematically, an example terminal block including amultiple recess sensor apparatus.

FIG. 2A shows, schematically, a top view of an example three positionterminal block jumper pass-through sensor apparatus.

FIG. 2B shows, schematically, a side view of an example three positionterminal block jumper pass-through sensor apparatus.

FIG. 3A shows, schematically, examples of jumper sensor apparatuses.

FIG. 3B shows, schematically, further examples of jumper sensorapparatuses.

FIG. 4 shows, schematically, examples of terminal lugs with monitoringsensor recesses.

FIG. 5A shows, schematically, an example of a terminal sensor clampapparatus.

FIG. 5B shows, schematically, another example of a terminal sensor clampapparatus.

FIG. 6 shows, schematically, an example of flexible terminal sensorclamp apparatus.

FIG. 7A shows, schematically, a combiner box with terminal sensorprobes.

FIG. 7B shows, schematically, a power device with terminal sensorprobes.

FIG. 7C shows, schematically, a power generation system with terminalsensor probes.

DETAILED DESCRIPTION

The accompanying drawings, which form a part hereof, show examples ofthe disclosure. It is to be understood that the examples shown in thedrawings and/or discussed herein are non-exclusive and that there areother examples of how the disclosure may be practiced.

Disclosed herein are sensor devices for detecting and preventingoverheating of terminal blocks. The sensor devices may comprise any of asensor, a conducting probe, a controller, and a body. The conductor maybe connected to an electrical conductor of the terminal block, such asthe conductor inserted into one or more recesses of a multiple contactterminal block and/or the conductor clamped on a terminal lug. Thecontroller may monitor the sensor, and when there is an abnormal sensorreading, the controller may initiate mitigating actions, notify a user,derate a power device, lower a current, and/or open a relay/switch. Forexample, when a sensor's value is above or below a threshold, thesensor's value may indicate that the resistance of the terminal block isabove a threshold, thereby producing more heat, comprising an increasedtemperature.

As used herein, the term controller means any sensor signal processingcircuit that may monitor the terminal block and when the sensor valuestrigger a monitoring rule, such as a rule associated with a hazardouscondition, an action is initiated by the controller to mitigate theabnormal sensor values. For example, the controller may be a centralprocessor, a hardware processor, a processing unit, a digital signalprocessor, a multicore processing unit, a field programmable gate array,an analog control circuit, and/or a digital control circuit.

The sensor may be a temperature sensor connected to a thermal conductor.When located within a recess of the terminal block, the thermalconductor contacts an internal electrical conductor of the terminalblock. When there is overheating of the internal conductor, thecontroller monitoring the sensor may take appropriate action to reducethe overheating, such as lowering the current through the terminalblock, notifying a user to tighten/replace the terminal block, and/orstopping operation of equipment attached to the terminal block.

The sensor may be a voltage sensor and the conductor contacts a terminallug connected to the terminal block. By comparing the voltage dropacross the terminal block and the current through the electricalconductor, the resistance of the terminal block may be monitored. Theresistance and current may determine the heat generation within theterminal block, and therefore monitoring the resistance may be used topredict when a high current may generate an overheating of the terminalblock. When the resistance is abnormal, such as above a threshold, anoutlier relative to historic resistance values, and/or an outlier whencompared to the resistance values of other terminal blocks, thecontroller monitoring the sensor may take appropriate action to reducethe resistance before the resistance causes the terminal block tooverheat.

According to some aspects, the recess of the terminal block may be usedfor jumpers, such as bridges, that may short circuit between twoterminal blocks. In some aspects, the recesses are on the forward facing(front) portion of the terminal block. In some aspects, the recesses arenear the electrical wire insertion cavity of the terminal block. Thesensor device may have a protruding structure configured to enter therecess, and a similar recess at the other side to accept a bridge orjumper for short circuiting between the terminal blocks. The combinationof protruding structure and recess, such as a male-female arrangement,may allow the sensor device to operate as a pass-through conductor forthe electrical connection and may also allow thermally coupling atemperature sensor to the terminal block conductor. Multiple sensordevices may be configured to be inserted as a single unit into multiplerecesses of one or more adjacent terminal blocks on the same DIN rail,such as multiple probes/sensors arranged in a comb-shaped structure. Themultiple probes/sensors may be electrically and/or thermally isolatedfrom each other so that a separate short-circuiting bridge deviceprovides a short-circuit connection between terminal blocks. Thetemperature sensors may be used to monitor the temperature of theconductor (and the terminals) of each terminal block individually and/orseparately.

Reference is now made to FIG. 1A, which shows, schematically, an exampleterminal block jumper pass-thru sensor apparatus 100. Apparatus 100comprises a conducting probe 101, one or more sensors such as at 104, anelectrical connection 105 to a controller 107, and the controller 107.The conducting probe 101 may be sized and shaped to be inserted into arecess (not shown) of a terminal block, a terminal lug, and/or anelectrical terminal. An insulating cover 103 may protect the conductingprobe from coming in electrical or thermal contact with othercomponents. A recess 102 may be included in the apparatus 100, and therecess 102 may allow a terminal block bridge or jumper (not shown, suchas WAGO® part number 870-404, Phoenix Contact part number 3032143,International Connector Inc. part number DSS4N-10P) to be inserted intothe recess, and thereby electrically connect to one or more internalconductors of the terminal blocks. The controller 107 may comprise ananalog to digital converter 106 (such as may be incorporated intoembedded controllers), and an interface 108 for communicating commandsto a power device, alerts to a power device, and/or notifications to auser interface. The controller 107 may be configured, such as usingcustomized program code, to monitor the temperature or voltage values ofthe terminal block conductor, and/or terminal lug. When the sensors' 104values (such as values representing a current, a voltage, a temperature,and/or an electromagnetic radiation) comply with an abnormality rule,the controller 107 may be configured to command a power device to lowerthe current flowing through the terminal block conductor (such as tolower the heat generated), send an alert to a power device using theinterface 108, and/or send an alert to a user interface (not shown)using the interface 108.

The interface 108 may comprise any of a digital data interface, anacoustic interface, a wireless interface, and/or a wired interface. Theinterface may be used to:

-   -   receive power from a power supply, a host device, a circuit        board, and/or a power converter,    -   send sensor data to a host device,    -   send alerts to a user interface,    -   send messages, warnings, critical alerts, and/or commands to a        host device.

Interface 108 may be implemented using electrical conductors, such as adata cable, a wireless interface, such as Bluetooth®, WiFi™, RFID,and/or Zigbee. A single interface may be used for multiple sensors tolower costs (such as assembly and/or components), and/or improvereliability (fewer components, connections, etc.). Multiple interfaces,such as combining a wireless interface and a wired interface, may beused to provide power with a wired interface and transmit apparatusgenerated data, such as sensor readings, alerts, warnings, and/ormessages.

One or more sensor apparatuses 100 may be incorporated into a terminalbox, junction box, power device, power converter, a power generationsystem, a power transfer system, an electrical cabinet, and/or a vehicleelectrical system. For example, sensor apparatuses may be incorporatedinto junction boxes between power devices of a power generation system,such as junction boxes between string inverters, parallel inverters,and/or power distribution systems. The sensor apparatus may send amessage to a host device/system, when a monitored sensor reports anabnormal value. For example, the message may be a digital messagecomprising one or more values (such as a command code or value, apercentage value, etc.) signaling the host device to lower the currentthrough the junction box.

A mechanical actuator may be controllable by the sensor apparatus 100,such as a mechanical lever, that disconnects a conductor, therebystopping a current flow through a terminal block. For example, anovercurrent protection device may be incorporated into a junction boxterminal block, and the controller of the sensor apparatus 100 may senda signal to the overcurrent protection mechanism to trigger anelectrical and/or mechanical disconnection of a mechanical lever. Themechanical actuator may be incorporated into a “fail-safe” terminalblock, for example that incorporates the sensor monitoring anddisconnects when overheating. For example, the apparatus comprising asensor and/or a controller, may be incorporated in or on a mechanicalelement used to electrically and/or mechanical disconnect the terminalblock internal conductor, such as using a knife blade disconnectelement, a circuit breaker element, and/or an , over-current protectionelement.

Reference is now made to FIG. 1B, which shows, schematically, an exampleterminal block jumper sensor apparatus 110. Many elements of thefigures, such as FIG. 1B, have similar corresponding elements in otherfigures, such as FIG. 1A, and for the sake of brevity in this document,at least some references to similar elements in other figures may beomitted but it may be identified that similar elements are set asalternative examples in different figures. The sensor apparatus 110 maycomprise a sensor 114 located in contact with a probe 111. Insulation113 may cover probe 111 at least in part. A connector 115 may be used totransfer a sensor reading, such as a sensor output voltage, from thesensor 114 to the controller 117. Controller 117 may convert the analogreading to a digital value, such as using an analog-to-digital converter116 (A/D). The controller 117 may be configured to monitor sensor 114readings, and when a sensor reading complies with an abnormal readingrule (such as stored on the controller, not shown) the controller 117may initiate an action to warn or mitigate the abnormal reading, such asby sending a command to a host device using the interface 118.

Reference is now made to FIG. 1C, which shows, schematically, an exampleterminal block 120 including multiple recess sensor apparatuses 130 and140. The terminal block 120 may comprise multiple recesses as at 121A,121B, and 121C. The sensor apparatuses 130 and 140 may compriseconducting probes 131 and 141, respectively, each configured in shapeand size to pass through one or more of the recesses 121A, 121B, and121C. When the sensor apparatus 130 or 140 enters one of the recesses121A, 121B, and 121C, a conducting probe 131 (or 141 for example),contacts an internal conductor 122 of the terminal block 120, therebyconducting a physical property of the internal conductor 122 to thesensor 132. The sensor apparatus 130 may comprise an electricalconductor 133 and a connector 134, that together transfer the electricalsignal from the sensor to a controller (not shown), such as a controlleron a circuit board. The sensor apparatus 140 may comprise a controller142, such as an embedded controller. The controller 142 may beincorporated in a power device, a control system, and/or a SupervisoryControl and Data Acquisition (SCADA) system. The controller 142 may beconfigured to:

-   -   draw power from two or more probes 141,    -   monitor sensors integrated with the probes 141,    -   calculate a compliance with a monitoring rule (stored on the        controller 142 or retrieved through a wireless interface 143),        and    -   when sensor reading is not compliant (such as an abnormal        reading—e.g., over-current over-temperature, etc.), initiate        actions to correct the physical property causing the abnormal        sensor reading, such as using the wireless interface 143 to send        a command to a power device to lower current through the        terminal block and/or notify a user interface of the abnormal        sensor reading.

The size of the conducting probe may be determined by the size of theterminal block recess (such as recesses 121A, 121B, and 121C), which inturn may be determined by the ampacity of the terminal block. Forexample, a terminal block for conducting 195 A may be configured for a12 mm diameter conductor or a 100 mm²) cross sectional conductor area. Arecess for this example may be of the same size or slightly larger toallow for insulation. For example, a jumper recess may have a 5 mm by 20mm rectangular shape, and/or a 10 mm by 10 mm square shape. Theconducting probe tip may comprise a cross section of between 1 and 300mm², depending on the terminal block ampacity.

Different makes and models of terminal blocks may have different shapedsizes of recesses, and have specially sized and shaped jumper bridges.Cross section area of the recess is controlled by the rated current, andmay be substantially equivalent to the cross section of the internalconductor or the connecting wire rating of the terminal. A sensorapparatus may have a combined shape and size to fit multiple makes andmodels of terminal blocks.

Reference is now made to FIG. 2A, which shows, schematically, a top viewof an example three position terminal block jumper pass-through sensorapparatus 200. The sensor apparatus 200 may comprise recesses 201 and aconnecting bridge 202, such as made from an insulating material. Theprobes (not visible in top view) may be configured with a cross-sectionshaped to enter a recess of a terminal block and connect to the internalconductor of the terminal block, such as comprising a cross-sectionshaped as a rounded rectangle, a squircle (i.e., a shape intermediatebetween a square and a circle), or a combination of square and roundshapes. For example, a rounded polygon shape may be configured tocontact the electrical conductor recess walls by pressing the roundedcorners (such as for a round shaped recess) and/or sides (such as for arectangular shaped recess) of the polygon against the internalconductor. This may have the benefit of a single probe configurationconnecting to the internal conductors of multiple makes and models ofterminal block recesses.

Reference is now made to FIG. 2B, which shows, schematically, a sideview of an example three position terminal block jumper pass-throughsensor apparatus 200. The sensor apparatus 200 may comprise multipleprobes 204 connected to a connecting bridge 202 of the sensor apparatus200 and may be arranged in a linear array, such as a comb structure.Each probe element of the linear array fits into a recess or a terminalblock arranged to match the comb/array structure (such as arranged inspacing, size and shape or probe elements). Recesses 201 may be locatedopposing the probe structures to allow connection of a jumper or bridgewhen needed. The sensor apparatus 200 may comprise multiple sensors 205,such as one for each probe 204, connected to a controller 207, such asserially through a multiplexor 206 (MUX). For example, the MUX 206 maysend multiple digital or analog values over one or more conductors bysharing the conductors for each sensor transfer. Once a first sensortransfer is complete, the MUX 206 may start sending the second sensorvalue. In this manner, multiple sensor values may be transferredserially. The controller 207 may comprise A/D converters 208 to convertthe sensor measurements to digital values. The controller 207 may beconfigured to monitor the sensor 205 values, and when one or more valuesis abnormal, an action or message is initiated by the controller 207using a data and/or communication interface 209.

In some configurations, adjacent terminal blocks may be of differentcurrent ratings and/or sizes, and the conducting probes of the sensorapparatus may be arranged non-linearly, such a zigzag pattern, atraverse or diagonal pattern, or a matching pattern. For example, eachprobe of the sensor apparatus has a different location corresponding tothe location of a recess in the terminal block that probe is configuredto enter.

Abnormal sensor values may be determined based on rules, such asdifferent from the other sensor values, different from previous sensorvalues, different from historically recorded sensor values, and/or abovea threshold relative to the current passing through the terminal blockassociated with specific probe and sensor. For example, a sensor valueof a temperature reading corresponding to a temperature of 95° C. maytrigger a device shutdown. For example, six sensors monitor six terminalblocks, and five of the sensors report a value corresponding to atemperature of 67° C. and one sensor is 87° C. and as a result a warningis sent to a user interface indicated an abnormal temperature at theterminal block of the 6^(th) sensor.

Reference is now made to FIG. 3A, which shows, schematically, examplesof sensor apparatuses 300, 310, 320, and 330. Probes, shown as the“teeth” of the linear array, may be arranged in differentconfigurations, such as a 10-probe sensor apparatus 300 with electricalconductors leading to a controller, a three-probe apparatus 310 with anintegrated controller, a two-probe sensor apparatus 320 configured foradjacent terminal blocks, a two-probe sensor apparatus 330 configuredfor non-adjacent terminal blocks (with a connector 331 to a printedcircuit board 332 comprising a controller 333). These examples show someof the different configurations of probes (such as matched to thespacing of the terminal blocks), and the integration between possibleexample sensor probes and configurations of the controller. For example,the controller may be on the probe, near the probe and connected withconductors to the sensors, integrated into a power device, and/orlocated on a remote server. Any of the example configurations of sensorprobes may be matched to any of the examples of the controllers, as longas the controllers are configured to support the specific number ofsensors on the probes.

Reference is now made to FIG. 3B, which shows, schematically, furtherexamples of sensor apparatuses, such as number of probes, positions ofprobes, etc.:

-   -   a two-probe apparatus for adjacent terminals as at 340A and        340B,    -   a two-probe apparatus for adjacent dissimilar terminals        (differently sized and shaped) as at 342A and 342B,    -   a 4-probe apparatus for adjacent terminals as at 344A and 344B,    -   a 10-probe apparatus for adjacent terminals as at 346A and 346B,    -   a three-probe apparatus for non-adjacent terminals as at 348A        and 348B,    -   a 10-probe apparatus for non-adjacent terminals as at 350.

The sensor probes may be inserted into recesses of terminal lugs, suchas terminal lugs connected to the terminal blocks. For example, a highterminal block rated for 250 A may use electrical cable connections ofterminal lugs, such as mechanical lugs. The terminal lug may include ahole or recess, into which a conducting probe may be inserted withassociated sensor, controller, etc.

Reference is now made to FIG. 4, which shows, schematically, examples ofterminal lugs 400 and 410 with monitoring sensor recesses. The terminallug 400 comprises a flange 401A and a terminal connection recess 401B. Abolt or screw is inserted through terminal connection recess 401B andtightened to electrically connect flange 401A to a terminal block. Anelectrical cable or wire is connected to the terminal lug 400 byinserting the bare conductor (such as after removal of insulation) intoa cable recess 403 and crimping the terminal lug body 402 around theconductor. A sensor recess 404 is positioned along flange 401A and thesensor apparatus probe inserted through recess 404 to allow the sensorattached to the probe to receive a physical property of the terminal,such as voltage and/or temperature. Terminal lug 410 is similar toterminal lug 400, but sensor recess 411B is located within a dedicatedbody element 411A protruding from the body of terminal lug 410. A sensorrecess on the terminal lug may be used for measuring the voltage ortemperature before the conductor reaches the terminal block (thusenabling the calculation of a temperature or voltage drop across theterminal block). In this configuration, the terminal block does notrequire a recess (such as a bridge or jumper recess). Since the probeand sensor may be incorporated into the terminal lug, fewer connectionsmay be needed to connect during installation and hence the reliabilitymay be improved over sensor apparatuses incorporated into the terminalblocks. Illustrated in FIG. 4 is a ring lug or eyelet lug, but similaraspects, with appropriate modification, may incorporate a fork lug, apin lug, and/or a flange lug.

Reference is now made to FIG. 5A, which shows, schematically, an exampleof a terminal sensor clamp apparatus 500. Some figures herein containmultiple similar parts, and where relevant, the references have beenmade to one of the parts. It may be understood that due to the analogousnature of the multiple parts, the description of one of the parts mayapply to the other corresponding parts. For example, when multiple lugsare arranged in a parallel manner to one of the lugs, as at 510.Apparatus 500 comprises a body 501 and a clamp 503 that may clamp arounda terminal lug (similar or identical to terminal lug 400 or 410 of FIG.4) as at 510, thereby connecting sensors (as at 508 and 509) to theseries of terminal lugs (as at 510). Body 501 and clamp 503 may compriseconducting probes for transferring a physical property from the terminallugs 510 to sensors 508 and 509, such as comprising a conductingmaterial (electrically conducting and/or thermally conducting). Theclamp 503 may have clamping teeth 507, one for each terminal lug 510.The clamp 503 may be pressed against the lugs using a spring or elasticdevice 511. The clamp 503 may be separated from terminal lugs 510 byusing a level 502 operating around pivot 505, that when opened away frombody 501 uses link arm 504 operating through pivots 506 to pull theclamping teeth 507 away from terminal lugs 510.

Reference is now made to FIG. 5B, which shows, schematically, anotherexample of a terminal sensor clamp apparatus 520. The apparatus 520comprises two sliding parts 521 and 522, where part 521 comprises ahandle 524 and clamping appendages 525, and part 522 comprises a handle523 and clamping appendages 526. Clamping appendages 525 and 526 may beconducting probes for transferring a physical property from terminallugs 530 to sensors 528, such as comprising a conducting material(electrically conducting and/or thermally conducting). An elastic member527 pulls clamping appendages 525 and 526 towards each other therebyapplying pressure to terminal lugs 530 between them and pressing sensors528 against terminal lugs 530. Operating handles 523 and 524 by graspingand pulling the handles towards each other, may allow inserting terminallugs 530 between clamping appendages 525 and 526.

Reference is now made to FIG. 6, which shows, schematically, an exampleof flexible terminal sensor clamp apparatus 600. Similarly to clampingappendages 525 and 526 of FIG. 5B, apparatus 600 comprises clamps as at605 and 606 which press sensors as at 607 and 608 against terminal lugs620. Clamps 605 and 606 may be conducting probes for transferring aphysical property from terminal lugs 620 to sensors 607 and 608, such ascomprising a conducting material (electrically conducting and/orthermally conducting). Elastic members 612, such as a spring, forcesclamps 605 and 606 (and sensors 607 and 608) against terminal lugs 620.Handle 604 may be attached to part 601, handle 603 may be attached topart 602, part 602 may be attached as at 613 to one opening cable as at611 per clamp pair, and cable 611 may penetrate first clamp 606 and maybe anchored as at 610 on second clamp 605. To open the clamps, handles603 and 604 may be pressed together, which may pull cables 611 such thatthe distal end of clamps 605 and 606 are pulled together, therebyopening the clamp for encompassing terminal lugs 620. Each clamp pairmay be connected to part 601 with a flexible neck 609, so that smallvariations in positions of terminal lugs 620 have minor effect on theclamping strength and mechanism. Flexible neck 609 may comprise alateral flexibility (side-to-side motion), and a longitudinal stiffness(along the length), enabling motion to the sides but allowing theopening clamp mechanism to operate.

The following FIG. 7A, 7B, and 7C depict example devices and systemsthat may incorporate aspects of a sensor apparatus coupled to anelectrical terminal, and as such, the terminal is depicted in theseexamples already incorporated into the AC or DC terminal, as the casemay be. Reference is now made to FIG. 7A, which shows, schematically, acombiner box 700 with terminal sensor probes. Combiner box 700 maycomprise terminals with sensors probes 702A, 702B, 702C, 702D, 702E, and702F, such as AC terminals (alternatively, the AC terminals may beconfigured for DC electrical power combining), each comprising a probeand sensor (not shown), such as the probes 101, 111, 131, 141, and 204,and sensors 104, 114, 132, 205, 508, 509, 528, 607, and 608 described inprevious figures. Power sources 703A, 703B, 703C, 703D, and 703E eachconnect to one of input terminals 702A, 702B, 702C, 702D, and 702E, andfor example output terminal 702F may be connected to an electrical grid701 and/or other power device (not shown). Combiner box 700 may comprisea controller (not shown—such as or similar to controllers 107, 117, 142,207, or 333) that monitors the sensors (such as or similar to sensors104, 114, 132, 141, 205, 508, 509, 528, 607, or 608), and when a sensorvalue exceeds a threshold, such as an over-temperature threshold, anover-resistance threshold, an over/under-voltage threshold, a overpowerdissipation threshold, and/or an abnormal terminal sensor valuethreshold (by comparing to other sensor values), the controller may senda message to a host system or user interface indicating the exceededthreshold and the terminal identifier (for assistance in initiating arepair of the faulty terminal).

Reference is now made to FIG. 7B, which shows, schematically, a powerdevice 710 with terminal sensor probes. Power device 710 may compriseterminals with sensor probes 712A, 712B, 712C, and 712D, which may be ACor DC terminals, each comprising a probe and a sensor (not shown—such asor similar to controllers 107, 117, 142, 207, or 333). Powersources/sinks 713, 714, and 715, may be connected to input terminalswith sensor probes 712B, 712C, 712A, respectively. For example, device715 may be a wind power generator connected to AC terminal 712A. Forexample, device 713 may be a solar power generator connected to DCterminal 712B. For example, device 714 may be an energy storage device,such as a residential home lithium ion battery, connected to DC terminal712C. Power device 710 may comprise an output terminal 712D connected toan electrical grid 711. Power device 710 may comprise a controller (notshown) that monitors the sensors, and when a sensor value exceeds athreshold, such as an over-temperature threshold, an over-resistancethreshold, an over/under-voltage threshold, a overpower dissipationthreshold, and/or an abnormal terminal threshold (by comparing to theother sensor values), the controller may send a message to a host systemor user interface indicating the exceeded threshold and the terminalidentifier (for assistance in initiating a repair of the faultyterminal).

Reference is now made to FIG. 7C, which shows, schematically, a powergeneration system 720 with terminal sensor probes. Power generationsystem 720 may comprise an inverter 721, a wind power generator 724,solar panels 726 (each connected using a junction box or optimizer726A), and/or electrical energy storage 725 (such as a battery).Inverter 721 may comprise terminals with sensor probes 722A, 722B, 722C,and 722D, which may be AC or DC terminals, each comprising an integratedprobe and sensor (not shown explicitly). Various power devices (such aswind power generator 724, electrical energy storage 725, and solarpanels 726 using devices 726A), may be connected to input terminals withrespective sensor probes 722B, 722C, and 722D. Inverter 721 via outputterminal with sensor probe 722A may be connected to electrical grid 723.Inverter 721 may comprise a controller (not shown) that monitors thesensors, and when a sensor value exceeds a threshold, such as anover-temperature threshold, an over/under-voltage threshold, anover-resistance threshold, a overpower dissipation threshold, and/or anabnormal terminal threshold (by comparing to the other sensor values),the controller may send a message to a host system or user interfaceindicating the exceeded threshold and the terminal identifier (forassistance in initiating a repair of the faulty terminal).

Here, as elsewhere in the specification and claims, ranges can becombined to form larger ranges.

Specific dimensions, specific materials, specific ranges, specificresistivities, specific voltages, specific shapes, and/or other specificproperties and values disclosed herein are example in nature and do notlimit the scope of the present disclosure. The disclosure herein ofparticular values and particular ranges of values for given parametersare not exclusive of other values and ranges of values that may beuseful in one or more of the examples disclosed herein. Moreover, it isenvisioned that any two particular values for a specific parameterstated herein may define the endpoints of a range of values that may besuitable for the given parameter (for example, the disclosure of a firstvalue and a second value for a given parameter can be interpreted asdisclosing that any value between the first and second values could alsobe employed for the given parameter). For example, if Parameter X isexemplified herein to have value A and also exemplified to have value Z,it is envisioned that parameter X may have a range of values from aboutA to about Z. Similarly, it is envisioned that disclosure of two or moreranges of values for a parameter (whether such ranges are nested,overlapping or distinct) subsume all possible combination of ranges forthe value that might be claimed using endpoints of the disclosed ranges.For example, if parameter Xis exemplified herein to have values in therange of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter Xmay have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8,2-3, 3-10, and 3-9.

In the description of various illustrative features, reference is madeto the accompanying drawings, which form a part hereof, and in which isshown, by way of illustration, various features in which aspects of thedisclosure may be practiced. It is to be understood that other featuresmay be utilized and structural and functional modifications may be made,without departing from the scope of the present disclosure.

Terms such as “multiple” as used in this disclosure indicate theproperty of having or involving several parts, elements, or members.

It may be noted that various connections are set forth between elementsherein. These connections are described in general and, unless specifiedotherwise, may be direct or indirect; this specification is not intendedto be limiting in this respect, and both direct and indirect connectionsare envisioned. Further, elements of one feature in any of theembodiments may be combined with elements from other features in any ofthe embodiments, in any combinations or sub-combinations.

All described features, and modifications of the described features, areusable in all aspects of the inventions taught herein. Furthermore, allof the features, and all of the modifications of the features, of all ofthe embodiments described herein, are combinable and interchangeablewith one another.

What is claimed is:
 1. An apparatus comprising: a conducting probeconfigured to couple with an electrical conductor of an electricalterminal of a power device; a sensor in contact with the conductingprobe; and a controller circuit electrically coupled to the sensor,wherein the controller circuit is configured to monitor values of thesensor, and the controller circuit is configured to initiate an actionto mitigate a hazardous condition when the values of the sensor complywith a monitoring rule associated with the hazardous condition.
 2. Theapparatus of claim 1, wherein the conducting probe is thermallyconductive, wherein the sensor is a temperature sensor, and whereincontact is thermal contact.
 3. The apparatus of claim 1, wherein theconducting probe is electrically conductive, wherein the sensor is avoltage sensor, and wherein contact is electrical contact.
 4. Theapparatus of claim 1, wherein the conducting probe is configured toenter a recess of the electrical terminal.
 5. The apparatus of claim 1,wherein the electrical terminal is incorporated into a terminal block.6. The apparatus of claim 5, wherein the terminal block is mechanicallycoupled to a DIN rail.
 7. The apparatus of claim 1, wherein theelectrical terminal comprises a terminal lug.
 8. The apparatus of claim7, wherein the conducting probe comprises a clamp mechanism to couplethe conducting probe to the terminal lug of the electrical terminal. 9.The apparatus of claim 1, wherein the apparatus is incorporated multipletimes with multiple conducting probes in a linear array.
 10. Theapparatus of claim 9, wherein the multiple conducting probes of thelinear array are configured to enter recesses of electrical terminalsarranged in a corresponding linear array.
 11. The apparatus of claim 9,wherein the multiple conducting probes comprise isolated electricalconnections, and the isolated electrical connections supply power to thecontroller circuit.
 12. The apparatus of claim 1, wherein the sensor isa temperature sensor, and further comprising a voltage sensor.
 13. Theapparatus of claim 1, further comprising a communication module forcommunication with a client terminal, wherein an action is initiatedusing the communication module to the client terminal.
 14. The apparatusof claim 1, wherein the action is at least one or a notification to auser and a lowering of current through the electrical terminal.
 15. Theapparatus of claim 1, further comprising an electrical insulatorsurrounding the conducting probe and the sensor.
 16. The apparatus ofclaim 1, wherein the conducting probe comprises a recess configured toreceive a jumper bridge, wherein the conducting probe is electricallycoupled to the electrical terminal and the jumper bridge, therebyelectrically coupling the electrical terminal and the jumper bridge. 17.The apparatus of claim 1, wherein the conducting probe is configured toenter a recess in a terminal lug.
 18. The apparatus of claim 1, whereinthe controller circuit is an analog controller circuit or a digitalcontroller circuit.
 19. A power device comprising: an electricalterminal comprising an electrical conductor; a conducting probeconfigured to couple with the electrical conductor of the electricalterminal; a sensor in contact with the conducting probe; and acontroller electrically coupled to the sensor, wherein the controller isconfigured to monitor values of the sensor, and the controller isconfigured to initiate an action to mitigate a hazardous condition whenthe values of the sensor comply with a monitoring rule associated withthe hazardous condition.
 20. A method comprising using a hardwareprocessor to: monitor values of a sensor, wherein the sensor is incontact with a conducting probe, wherein the conducting probe is coupledwith an electrical conductor of an electrical terminal, wherein theconducting probe is configured to be inserted into a recess of theelectrical terminal; and when values of the sensor comply with a ruleassociated with a hazardous condition, initiate an action to mitigatethe hazardous condition.